Pattern former for wrapped bakery products

ABSTRACT

A pattern former for assembling wrapped bakery products into predetermined patterns includes a vacuum turntable comprising a perforated plate which is driven by a belt extending around the periphery of the vacuum turntable and actuated by a motor. A first transfer apparatus includes a pusher plate which moves groups of wrapped bakery products onto the vacuum turntable and which retracts to facilitate the formation of a subsequent group of wrapped bakery products as a previous group is being transferred to the vacuum turntable. A second transfer apparatus includes a pusher plate which moves assembled patterns of wrapped bakery products from the vacuum turntable into bakery trays and which is retractable to facilitate the assembly of a subsequent pattern of wrapped bakery products as a previous pattern is being transferred to a bakery tray.

Continuation of prior application No.: 09/587,127, filed Jun. 2, 2000Which is a: Continuation-in-part (CIP)of prior application No.:60/159,627, filed Oct. 14, 1999.

TECHNICAL FIELD

This invention relates generally to pattern formers for bakery products,and more particularly to apparatus for assembling wrapped bakeryproducts into predetermined patterns prior to the loading thereof intobakery trays.

BACKGROUND AND SUMMARY OF THE INVENTION

The operation of a modern commercial bakery in the manufacture of bakeryproducts such as sliced bread loaves begins with the preparation ofdough which is deposited into baking pans, proofed, and baked.Thereafter, the baked loaves of bread are removed from the pans, cooled,sliced, wrapped in plastic film, and loaded into bakery trays fordelivery to retail outlets.

As is well known, bread and other wrapped bakery products such ashamburger buns, hot dog buns, etc. are available in a seemingly infinitenumber of sizes. However, commercial bakeries do not typically providebakery trays which are configured to receive particular bakery products.Rather, commercial bakeries typically employ one type, or at most a fewtypes, of bakery trays which are used to receive and transport a widevariety of bakery products.

Prior to being loaded into bakery trays, bakery products are arranged inpredetermined patterns, the purpose being to assure the most efficientloading of a particular tray configuration with a particular bakeryproduct to be received therein. In addition to loading efficiency, thepositioning of the tails of the wrapped bakery products, that is, theopenable ends thereof which are tied or otherwise secured duringtransport, is also taken into consideration. Preferably, the tails ofthe wrapped bakery products face inwardly thereby preventing snagging ortearing during transport.

The apparatus that is used to arrange wrapped bakery products inpredetermined patterns prior to the loading thereof into bakery trays isknown as a pattern former. Typically, a pattern former receivesindividually wrapped bakery products from the wrapping apparatus,arranges the received wrapped bakery products in groups comprisingbetween 1 and about 6 wrapped bakery products, assembles at least 2 andas many as several groups of wrapped bakery products relative to oneanother to form the predetermined pattern, then positions the entirepattern of wrapped bakery products in a bakery tray for transport. U.S.Pat. No. 4,522,292 granted to Euverard, et al. on Jun. 11, 1985; U.S.Pat. No. 4,856,263 granted to Schneider, et al. on Aug. 15, 1989; andU.S. Pat. No. 5,317,859 granted to Schneider, et al. on Jun. 7, 1994illustrate and describe prior art pattern formers. The pattern formersof the prior art are relatively complex in design and are thereforecostly to purchase and maintain. Perhaps more importantly, prior artpattern formers are relatively slow in operation, achieving the maximumrate of about 60 loaves per minute. This means that several of the priorart pattern formers are required in order to till bakery trays withwrapped bakery products at a rate that is compatible with the output ofa typical bakery product wrapping apparatus.

The present invention comprises an improved pattern former for wrappedbakery products which overcomes the foregoing and other deficiencieswhich have long since characterized the prior art. In particular, thepattern former of the present invention has an operational speed of 100loaves per minute which means that a significantly smaller number ofpattern formers is required in order to fulfill the pattern formingrequirements of the modern commercial baking operation. This results insubstantial savings to the bakery operator both in terms of initial costand in terms of maintenance requirements.

The use of pattern formers incorporating the present invention is alsoadvantageous in that pattern formers constructed in accordance with theinvention are adapted to receive wrapped bakery products along the sameaxis and from the same bakery product inputting devices that have beenused to supply pattern formers of the prior art, and to deliver filledbakery trays along the same axis and to the same bakery tray receivingapparatus that has been used with prior art pattern formers. This meansthat the pattern former of the present invention can be installed in anexisting bakery without reconfiguring the bakery and withoutrepositioning the apparatus which deliver wrapped bakery products to andreceive tilled bakery trays from the pattern former.

More particularly, the pattern former of the present invention employs avacuum turntable to receive groups of wrapped bakery products and toassemble the groups of wrapped bakery products into patterns. The use ofthe vacuum turntable of the present invention is advantageous in that bymeans thereof wrapped bakery products are received and accuratelypositioned within predetermined patterns without damage either to thebakery products or the wrapping thereof.

The pattern former of the present invention further includes apparatusfor transferring groups of wrapped bakery products onto the vacuumturntable while simultaneously assembling a second group of wrappedbakery products. A similar apparatus transfers patterns of wrappedbakery products into bakery trays while a subsequent pattern issimultaneously being formed. As will be appreciated by those skilled inthe art, the ability of the pattern former of the present invention toperform multiple tasks simultaneously significantly increases thethroughput rate of the pattern former.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the invention may be had by referenceto the following Detailed Description when taken in conjunction with theaccompanying Drawings, wherein:

FIG. 1 is a perspective view of a pattern former incorporating theinvention;

FIG. 2 is a top view of the pattern former of FIG. 1;

FIG. 3 is an enlargement of a portion of FIG. 2;

FIG. 4 is a side view of the pattern former of FIG. 1;

FIG. 5 is a perspective view illustrating the vacuum turntable and theapparatus for filling bakery trays with patterns of wrapped bakeryproducts comprising the pattern former of FIG. 1;

FIG. 6 is an end view of the apparatus of FIG. 5;

FIG. 7 is a front perspective view of the apparatus for transferringpatterns of wrapped bakery products into bakery trays comprising thepattern former of FIG. 1;

FIG. 8 is a rear perspective view of the apparatus of FIG. 7;

FIG. 9 is an enlargement of a portion of FIG. 8;

FIG. 10 is a bottom perspective view of a portion of the apparatus ofFIG. 8;

FIG. 11 is an enlargement of a portion of FIG. 7;

FIG. 12 is an illustration of an initial step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 13 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 14 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 15 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 16 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 17 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 18 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 19 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 20 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 21 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 22 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 23 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 24 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 25 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 26 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 27 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 28 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 29 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 30 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 31 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 32 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 33 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 34 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 35 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 36 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 37 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 38 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 39 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 40 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 41 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 42 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 43 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 44 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 45 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 46 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 47 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 48 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 49 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 50 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 51 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 52 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 53 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 54 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 55 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 56 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 57 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 58 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 59 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 60 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 61 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 62 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 63 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 64 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 65 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 66 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 67 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 68 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 69 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 70 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 71 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 72 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 73 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 74 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 75 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 76 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 77 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11;

FIG. 78 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11; and

FIG. 79 is an illustration of a subsequent step in the operation of theapparatus shown in FIGS. 5-11.

DETAILED DESCRIPTION

Referring now to the Drawings, and particularly to FIG. 1, there isshown a pattern former 100 incorporating the present invention. Thepattern former 100 includes a frame 102 which supports the variouscomponent parts of the pattern former. The frame 102 is conventional indesign and may comprise lengths of tubular, channel, or bar stock whichare secured together by welding or by means of conventional fasteners.

The pattern former 100 includes an intake conveyor 104 which receiveswrapped bakery products from a conventional wrapped bakery productinputting apparatus such as the delivery conveyor of a bakery productwrapping apparatus. A gating conveyor 106 receives wrapped bakeryproducts from the intake conveyor 104 and delivers wrapped bakeryproducts to a grouping apparatus 108. The intake conveyor 104, thegating conveyor 106, and the grouping apparatus 108 function to arrangewrapped bakery products received by the pattern former 100 in groups ofwrapped bakery products, each group comprising from between 1 to about 6wrapped bakery products depending on the particular pattern of wrappedbakery products to be formed.

The pattern former 100 further includes a transfer apparatus 110 whichtransfers groups of wrapped bakery products from the grouping conveyor108 onto a vacuum turntable 112. An important feature of the presentinvention comprises the fact that the transfer apparatus 110 is adaptedto transfer a first group of wrapped bakery products to the vacuumturntable 112 while a subsequent group of wrapped bakery products isbeing arranged on the grouping apparatus 108. The ability of the patternformer of the present invention to perform these two functionssimultaneously comprises a significant improvement over the prior artwhich results in the pattern former of the present invention having asignificantly improved throughput rate when compared with prior artpattern formers.

The vacuum turntable 112 functions to receive groups of wrapped bakeryproducts from the transfer apparatus 110 and to assemble the groups ofwrapped bakery products into predetermined patterns. After apredetermined pattern of wrapped bakery products is formed, a transferapparatus 116 transfers the pattern of wrapped bakery products from thevacuum turntable 112 to a bakery tray.

An important feature of the present invention comprises the fact thatthe transfer apparatus 115 is adapted to transfer a pattern of wrappedbakery products from the vacuum turntable 112 to a bakery tray while asubsequent pattern of wrapped bakery products is being assembled on theturntable 112. The ability of the pattern former of the presentinvention to perform these two functions simultaneously comprises asignificant improvement in that it substantially increases thethroughput rate of the pattern former of the present invention whencompared with prior art pattern formers.

Vacuum is applied to the vacuum turntable 112 by a vacuum generatingapparatus 118 situated beneath the vacuum turntable 112. The vacuumgenerating apparatus 118 typically comprises a vacuum pump and amanifold connected to the vacuum pump for applying the vacuum evenlyacross the entire diameter of the vacuum turntable 112. As will beappreciated by those skilled in the art, other types and kinds of vacuumgenerating apparatus may be utilized in the practice of the inventiondepending upon the requirements of particular applications thereof. Theintensity of the vacuum that is applied to the vacuum turntable 112 islikewise dependent on the diameter of the vacuum turntable, therotational speed at which the vacuum turntable is operated, and thetypes and kinds of wrapped bakery products which are handled by thevacuum turntable.

Referring particularly to FIGS. 3 and 4, the turntable 112 is driven bya motor 120. A pulley 122 is driven by the motor 120 and in turn drivesa belt 124. The belt 124 extends entirely around the turntable 112 andfunctions to transfer operating power from the motor 120 to theturntable 112. The rotation of the vacuum turntable 112 is guided by aplurality of idler rollers 126 located at spaced intervals around theperiphery of the turntable 112.

The use of the belt 124 to rotate the turntable 112 comprises animportant feature of the invention. By means of the turntable drivesystem of the present invention, the high torque loads which aretypically imposed on turntable drive shafts are eliminated. Perhaps moreimportantly, by eliminating the typical turntable drive shaft, the spacedirectly beneath the turntable is made available for the vacuumgenerating apparatus 118 which applies vacuum to the turntable withoutinterference from the turntable operating mechanism. In this manner, thevacuum is supplied uniformly across the entire diameter of the turntable112.

The upper surface of the vacuum turntable 112 which engages the wrappedbakery products, comprises a perforated plate 132. The diameter of theperforations comprising the plate 132 is preferably between about 0.0337inches and about 0.0340 inches. The spacing between the holes comprisingthe perforated plate 132 is preferably between about 0.2186 inches andabout 0.2225 inches. The thickness of the perforated plate 132 ispreferably about 0.020 inches, however, thicker plates can also be usedin the practice of the invention, if desired. Those skilled in the artwill appreciate and understand the fact that the precise dimensionscomprising the diameters of the perforations, the spacing betweenperforations, and the thickness of the perforated plate 132 of thevacuum turntable 112 can be varied in accordance with the requirementsof particular applications of the invention.

The vacuum turntable 112 performs two very important functions in theoperation of the pattern former 100. First, the vacuum turntable 112decelerates individual wrapped bakery products comprising groups ofwrapped bakery products which are moved onto the vacuum turntable 112 bythe transfer apparatus 110. In this manner each wrapped bakery productcomprising a group thereof is precisely positioned on the vacuumturntable 112 without danger of the wrapped bakery product moving beyondits intended location due to inertia. The vacuum turntable 112 alsofunctions to firmly retain the wrapped bakery products received thereonduring rotation of the vacuum turntable 112 to form the desired patternof wrapped bakery products. This is true even if the wrapped bakeryproducts are positioned near the outer circumference of the vacuumturntable 112. Perhaps most importantly, the vacuum turntable 112properly decelerates wrapped bakery products received thereon andsubsequently firmly retains the wrapped bakery products during rotationwith no damage to the bakery products or the wrapping thereof.

FIGS. 5-11, inclusive, illustrate the construction and operation of theapparatus 116 which transfers patterns of wrapped bakery products fromthe vacuum turntable 112 to bakery trays for transportation from thebakery to retail outlets. The apparatus 116 includes a housing 134 whichencloses a drive belt 136. The drive belt 136 moves along a coursedefined by pulleys 138 and is driven by a motor 140. A traveler 142 issecured to the belt 136 for movement thereby along a substantiallyhorizontal course defined by slideways 144. The slideways 144 supportthe traveler 142 for movement under the action of the belt 136.

The traveler 142 supports a pusher plate 150 and a spanker plate 152.The pusher plate 150 is actuated by pusher plate cams 154 and thespanker plate 152 is actuated by spanker plate cents 156.

As is best shown in FIGS. 8, 9, 20, and 11, the pusher plate 150 issupported on a rod 160 which is pivotally supported on the traveler 142.A bell crank 162 extends from each end of the rod 160, and a camfollower 164 is supported at the distal end of each bell crank 162. Theweight of the pusher plate 150 normally pivots the pusher plate 150downwardly thereby pivoting the cam followers 164 upwardly and intoengagement with camming surfaces comprising the lower surfaces of thepusher plate cams 154.

The pusher plate cams 154 include pivotally supported sections 166. Asthe pusher plate 150 moves away from the turntable 112 and toward themotor 140, the cam followers 164 engage the pivotally supported portions166 which thereupon pivot upwardly allowing the cain followers 164 tocontinue in engagement with the lower camming surfaces of the pusherplate cams 154.

When the pusher plate 150 reaches the end of its travel away from theturntable 112 and toward the motor 140, the direction of movement of thebelt 136 is reversed and the pusher plate 150 is moved in the oppositedirection, i.e., away from the motor 140 and toward the turntable 112.The cam followers 164 engage the pivotally supported portions 166 of thepusher plate cams 154 thereby causing the cam followers 164 to rideupwardly and into engagement with upper camming surfaces comprising thepusher plate cams 154. Engagement of the cam followers 164 with theupper camming surfaces of the pusher plate cams 154 pivots the pusherplate 150 upwardly into an orientation in which it extends parallel tothe pusher plate earns 154. This allows the pusher plate 150 to passover a pattern of wrapped baked goods which has been assembled on thevacuum turntable 112 as the pusher plate 150 was moving a previouslyassembled pattern of f the turntable 112 and into a bakery tray. Thespanker plate 152 is supported on rods 172 which are sidedly supportedin the traveler 142. The rods 172 extend to a bar 174 which in turnextends to cam followers 176 which engage the spanker plate cams 156. Aswill be appreciated by those skilled in the art, the spanker plate cams156 allow the spanker plate 152 to move downwardly as the traveler 142reaches the limit of its travel in the direction extending away from thevacuum turntable 112 and towards the motor 140. As the traveler 142begins its reverse movement, i.e., away from the motor 140 and towardthe vacuum turntable 112, the spanker plate cams 156 return the spankerplate 152 to the position illustrated in FIGS. 5-11, inclusive.

The operation of the transfer apparatus 116 of the pattern former 100 isillustrated in FIGS. 12-79, inclusive. A plurality of wrapped bakeryproducts P are positioned on the vacuum turntable 112. A bakery tray Tis positioned to receive the wrapped bakery products P. A slip sheet 180extends from the vacuum turntable 112 into the bakery tray T. The pusherplate 150 extends downwardly and engages the wrapped bakery products P.Under the action of the motor 140 operating through the belt 136, thepusher plate 150 begins to push the wrapped bakery products P toward thebakery tray T.

FIGS. 12-42, inclusive, depict the movement of the wrapped bakeryproducts P away from the vacuum turntable 112 and into the bakery tray Tunder the action of the pusher plate 150. As will be appreciated bythose skilled in the art, the wrapped bakery products P follow a slidingmovement downwardly along the upper surface of the slip sheet 180 as thewrapped bakery products P enter the bakery tray T.

Referring particularly to FIGS. 43-53, the movement of the wrappedbakery products P into the bakery tray T under the action of the pusherplate 150 eventually causes the bakery tray T to move away from thevacuum turntable 112 thereby disengaging the slip sheet 180 therefrom.FIGS. 48-53 illustrate the pivotally supported portion 166 of the pusherplate cam 154 pivoting upwardly to allow the cam followers 164 to passthereunder.

FIGS. 53-63, inclusive, illustrate the final position of the movement ofthe wrapped bakery products P into the bakery tray T. The cam followers176 eventually reach the end of the flat portions of the spanker platecams 156 whereupon the spanker plate 152 is allowed to move downwardly.As will be appreciated by those skilled in the art, the spanker plate152 is not forced downwardly, but instead moves downwardly under theaction of gravity. The function of the spanker plate 152 is to assurethat the last wrapped bakery product P comprising the pattern that wasformed on the vacuum turntable 112 is fully seated in the bakery tray T.Simultaneously, the slip sheet 180 is fully disengaged from the bakerytray T as the bakery tray T moves away from the vacuum turntable 112under the action of the pusher plate 150.

FIGS. 64-79, inclusive, illustrate the return movement of the traveler142 and the apparatus carried thereby, that is, the movement of thetraveler 142 away from the motor 140 and toward the vacuum turntable112. As the cam followers 176 move into engagement with the inclinedportion of the spanker plate cams 156, the spanker plate 152 is movedupwardly. As the cam followers 164 engage the pivotally supportedportions 166 of the pusher plate cams 154, the pusher plate 150 ispivoted upwardly until it extends parallel to the belt 136.

Upward movement of the spanker plate 152 and upward plate 150 and thespanker plate 152 to pass over a subsequent pattern of wrapped bakeryproducts that was formed on the vacuum turntable 112 as the pusher platewas moving the previously formed pattern of wrapped bakery products intothe bakery tray T. The fact that a pattern of wrapped bakery productscan be moved into a bakery tray and a subsequent pattern of wrappedbakery products can simultaneously be formed on the vacuum turntable 112comprises an important feature of the present invention whichsubstantially increases the throughput rate of pattern formersincorporated in the invention.

Referring particularly to FIGS. 76-79, inclusive, when the cam followers164 reach the ends of the upper surfaces of the pusher plate cams 154,the pusher plate 150 drops down under the action of gravity and returnsto its original positioning. The spanker plate 152 remains in its raisedorientation under the action of the engagement of the cam followers 176with the spanker plate cams 156. FIG. 79 illustrates the component partsof the apparatus 116 in their original orientation and ready to move asubsequent pattern of wrapped bakery products into a bakery tray.

The transfer apparatus 110 which moves groups of wrapped bakery productsfrom the grouping apparatus 108 to the vacuum turntable 112 operatesexactly the same as the transfer apparatus 116, the only differencebeing that the transfer apparatus 110 does not include a spanker Thetransfer apparatus 110 includes a pusher plate 182 which is mounted on abelt driven traveler constructed similarly to and functioningidentically to the traveler 142 and which is activated by camsconstructed similarly to and functioning identically tot the cams 154.Thus, the transfer apparatus 110 operates identically to the operationof the pusher plate 150 of the transfer apparatus 116 in that it ispositioned in a downwardly extending, operative orientation as it movesgroups of bakery products from the grouping apparatus 108 to the vacuumturntable 112, and is cammed upwardly into a horizontally disposedorientation as it moves in the reverse direction, that is, away from thevacuum turntable 112 and back toward the grouping apparatus 108. In thismanner the pattern former of the present invention functions to arrangea subsequent group of wrapped bakery products on the grouping apparatus108 as the pusher plate 182 is moving a previous group of wrapped bakeryproducts onto the vacuum turntable 112. The fact that the two operationsoccur simultaneously comprises an important feature of the patternformer 100 which substantially increases the throughput rate thereof.

Although preferred embodiments of the invention have been illustrated inthe accompanying Drawings and described in the foregoing DetailedDescription, it will be understood that the invention is not limited tothe embodiments disclosed, but is capable of numerous and elementswithout departing from the spirit of the invention.

What is claimed is:
 1. In a pattern former of type adapted to receivewrapped bakery products, to assemble the received wrapped bakeryproducts into a predetermined pattern, and to transfer the predeterminedpattern into a bakery tray, improvement comprising: a turntable forreceiving wrapped bakery products in groups and for assembling thereceived groups of wrapped bakery products into a predetermined pattern;the turntable comprising a perforated plate characterized byperforations having predetermined diameters and predetermined spacingbetween perforations; means for establishing a predetermined vacuumwithin the perforations of the turntable; a turntable drive apparatusincluding drive means engaging the exterior of the turntable and a drivemotor for actuating the drive means to position the turntable to receiveand orient groups of wrapped bakery products.
 2. The improvementaccording to claim 1 wherein the perforations comprising the perforatedplate of the turntable are characterized by diameters of between about0.0337 inches and about 0.0340 inches.
 3. The improvement according toclaim 1 wherein the adjacent perforations on the perforated plate of theturntable are spaced apart by a distance of between about 0.2186 inchesand about 0.2225 inches.
 4. The improvement according to claim 1 whereinthe perforated plate of the turntable is characterized by a thickness ofat least about 0.020 inches.
 5. The improvement according to claim 1further including a grouping apparatus for collecting individual wrappedbakery products into groups comprising between 1 and about 6 individualwrapped bakery products prior to the transfer of the groups of wrappedbakery products onto the turntable.
 6. The improvement according toclaim 5 further characterized by a pusher plate for moving wrappedbakery products from the grouping apparatus onto the turntable forassembly thereby into predetermined patterns of wrapped bakery products.7. The improvement according to claim 6 further including apparatus forpositioning the pusher plate in a substantially vertical orientationduring the movement of wrapped bakery products from the groupingapparatus onto the turntable under the action of the pusher plate andfor positioning the pusher plate in a substantially horizontal apparatusduring return movement Thereof, thereby facilitating the arranging of asubsequent group of wrapped bakery products on the grouping apparatusduring the movement of a previous group of wrapped bakery products fromthe grouping apparatus onto the turntable.
 8. The improvement accordingto claim 1 further characterized by a slip sheet extending from theturntable and a pusher plate for moving patterns of wrapped bakeryproducts from the turntable along the slip sheet and into bakery trays.9. The improvement according to claim 8 further characterized byapparatus for positioning the pusher plate in a vertical orientationduring movement of patterns of wrapped bakery products into bakeryreceiving trays under the action of the pusher plate and for positioningthe pusher plate in a horizontal orientation during return movementthereof, thereby facilitating the assembly of a subsequent pattern ofwrapped bakery products on the turntable during movement of a previouspattern of wrapped bakery products from the turntable into a bakerytray.
 10. The improvement according to claim 9 further including aspanker plate and apparatus for reciprocating the spanker platevertically to assure the positioning of the trailing portion of apattern of bakery products in the receiving bakery tray.
 11. In apattern former of a type adapted to receive wrapped bakery products, toassemble the received wrapped bakery products into a predeterminedpattern, and to transfer the predetermined pattern into a bakery tray,an improvement comprising: a turntable comprises a perforated platecharacterized by perforation having predetermined diameters andpredetermined spacing between perforation, and further including meansfor establishing a predetermined vacuum within the perforations; atransfer apparatus including a pusher plate for moving groups of wrappedbakery products onto the turntable and retractable to facilitate forminga subsequent group of wrapped bakery products as a previous group ofwrapped bakery products is being transferred to the turntable.
 12. Theimprovement according to claim 11 wherein the perforations comprisingthe perforated plate of the turntable are characterized by diameters ofbetween about 0.0337 inches and about 0.0340 inches.
 13. The improvementaccording to claim 11 wherein the adjacent perforations on theperforated plate of the turntable are spaced apart by a distance ofbetween about 0.2186 inches and about 0.2225 inches.
 14. The improvementaccording to claim 1 wherein the perforated plate of the turntable ischaracterized by a thickness of at least about 0.020 inches.
 15. In apattern former of a type adapted to receive wrapped bakery products, toassemble the received wrapped bakery products into a predeterminedpattern, and to transfer the predetermined pattern into a bakery tray,an improvement comprising: a turntable comprises a perforated platecharacterized by perforations having predetermined diameters andpredetermined spacing between perforations, and further including meansfor establishing a predetermined vacuum within the perforations; atransfer apparatus for moving predetermined patterns of wrapped bakeryproducts from the turntable into bakery trays comprising a pusher platenormally disposed to move patterns of wrapped bakery products from theturntable into bakery trays and retractable to facilitate the assemblyof a subsequent pattern of wrapped bakery products while a previouspattern of wrapped bakery products is being moved from the turntable toa bakery tray.
 16. The improvement according to claim 15 wherein theperforations comprising the perforated plate of the turntable arecharacterized by diameters of between about 0.0337 inches and about0.0340 inches.
 17. The improvement according to claim 15 wherein theadjacent perforations on the perforated plate of the turnable are spacedapart by a distance of between about 0.2186 inches and about 0.2225inches.
 18. The improvement according to claim 15 wherein the perforatedplate of the turntable is characterized by a thickness of at least about0.020 inches.